Co-simulation analysis of the bearing cage in the dynamic state

• The validated co-simulation model accurately reproduces the stress–strain response of large bearing cages. • Simulation outcomes show strong agreement with experimental measurements across different load and speed conditions. • The proposed procedure enables identification of critical stress concentration zones and supports cage geometry optimization. • The simulation model provides a reliable basis for cage dimensioning and service life prediction under cyclic loading. • The methodology is suitable for further development of bearings in highly loaded applications, particularly in wind power systems. This paper deals with stress-deformation simulations of cages of large-scale rolling bearings for wind power plants, supported by experimental measurements of the tension of the investigated cages to verify the created simulation models. The paper aims to design co-simulation models of cage loading so that it is possible to simulate their different loading conditions for the required operating modes. The simulation model is built on the cooperation of dynamic analysis, which will determine the cage's load during the simulation of the operational mode. In contrast, static structural analysis will determine stress-deformation characteristics in the operational mode. In co-simulation using the Adams model, it is possible to increase the accuracy of the model by incorporating geometrically and materially nonlinear structural behavior. Additionally, in Marc, which employs the finite element method, it is possible to study components under realistic boundary conditions. This provides a significant time saving for users of the nonlinear finite element method, as some rigid moving parts can be simulated in the Adams model instead of the finite element environment, dramatically reducing the overall solution time. As part of the paper, a method of measuring cage deformations on a selected type of large-sized bearing on the testing apparatus is proposed. The results obtained from the co-simulation models are verified with the results from the experimental measurements.